Condition Monitoring Tata

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IMPROVING EQUIPMENT AVAILABILITY AND RELIABILITY

THROUGH CONDITION MONITORING AT COLD ROLLING MILL
COMPLEX OF TATA STEEL
G.R.P. Singh, A.K. Paul, A.K. Chaterjee, P.S.S. Ganesh, C. Mishra
Abstract:
Maintenance of plant and equipment is carried out to increase the
availability and reliability, so that it will continue to operate
satisfactorily for the entire life-cycle of the equipment with required
cost effectiveness. There are three main categories of maintenance
strategies:
• Corrective or Breakdown Maintenance
• Preventive (Periodic or Fixed Time Based) Maintenance
• Condition Based Maintenance (CBM) or Proactive Maintenance
In CBM, Maintenance is carried out only when there is a need, as
indicated by the measurement and analysis, using some of the
several available condition monitoring techniques. These techniques
include use of parameters like vibration and noise, temperature,
lubricant condition, wear debris analysis, corrosion, pressure, flow
and other performance parameters.
This paper deals with condition monitoring techniques being used at
CRM for different equipment and its benefits.
Introduction
Managing industry in 21st century is a challenging task. Last few
decades can be earmarked for the all round industrial development.
Continuous improvement in the area of technology, productivity and
quality has resulted in a cutthroat competition in the industries.
Today, industries are striving to achieve improvement in efficiency in
all the fronts to have more competitive edge over other similar
industries. Therefore each operation in business is critically
1
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examined to enhance profitability. To be more competitive industry,

one must be concerned about the following:
Product quality
Productivity
Customer satisfaction
Cost of manufacturing
Improvement in Product quality, productivity and reduction in cost of
manufacturing can be achieved by switching over to new and
economic technology and by increasing the equipment availability
and reliability. The cost of product must be lowest with highest grade
of quality. Here, maintenance is playing important role in any
business. Plainly stated, the growing cost of maintenance is a
serious business aspect and maintenance is the largest single
controllable expenditure in a plant or industry.
Predictive maintenance generally known as condition based
maintenance and proactive maintenance management is becoming
the system of choice for the industry to achieve higher machine
reliability and in turn to be cost competitive in the market. The gains
offered by condition monitoring and proactive maintenance go far
beyond traditional preventive and breakdown maintenance.
Condition based maintenance is a holistic multidiscipline based on
system thinking. It encompasses instrumentation, engineering,
information technology and management. Role of Condition
monitoring activities to achieve higher level of Equipment Availability
and Reliability in CRM of Tata Steel is discussed in brief in the
following paper.
Condition monitoring
Condition monitoring involves determining the condition of a machine
and its rate of change of measured parameters in order to determine
the maintenance requirement. The condition of machine may be
determined continuously or at regular intervals by monitoring
measurable parameters.
2
CORRECTION
CM DATA
CBM is carried out for two main reasons:
1.To detect sudden changes in condition that could lead to

catastrophic failure, particularly for machinery that could represent a
threat to the health and safety of people, or cause an environmental
incident. This is known as 'Machinery Protection' or 'Protective
Monitoring'.
2. To identify the early onset of incipient failures so that a prediction

can be made about their most likely progress and suitable actions
can be planned. This is known as 'Predictive Monitoring' or 'Predictive
Maintenance', and is often abbreviated to 'PDM'.
Potential benefits:
In the year 1988, Technology for Energy Corporation studied impact
of condition monitoring over 500 plants in USA, UK Canada and
Australia. A significant fact emerged out that systematic
3
implementation of condition monitoring can reduce the maintenance

cost of about more than 50 percent. Other benefits achieved by the
plants having condition monitoring activities are as follows:
Reduction in forced shutdown
Reduction in spares inventory
Reduction in shutdown time
Improvement in machine reliability and availability
Increasing equipment operating life
Improvement in safety margin
Improvement in machine performance & output quality
Increasing bottom line profit
Condition monitoring techniques:
A wide range of Condition monitoring techniques is available and
some have become standards in many industries. Those "standard"
technologies include vibration analysis, ultrasound, oil analysis, wear-
particle analysis, Industrial Videoscope System and thermography.
Vibration analysis is used primarily with rotating equipment to find
problems such as out-of-balance, looseness, misalignment, gear
teeth defects, bearing defects and system resonance. Generally
periodic readings are taken and recorded. Maintenance personnel
then compare these readings to a baseline. When vibration reaches a
certain level, then root cause of high vibration is analyzed and
corrective action plan is drawn. This reduces the amount of reactive
maintenance and ensures the replacement occurs with minimum
impact on the production or facility schedule.
Ultrasound function is primarily used for leak detection, particularly
for steam and air leaks. Ultrasound is also used to detect cavitation
problems in hydraulic pumps. Other applications include the
detection of electrical problems. Loose connections in junction boxes
and bus bars can be monitored for the sounds of arcing. This
technique is useful in power distribution centers and motor control
rooms.
4
Oil and Wear-Particle Analysis: Oil analysis and wear-particle

analyses are actually two very different technologies. Oil analysis
determines the condition of a lubricant. Wear-particle analysis
determines the condition of equipment based on the concentration of
wear particles in the lubricant.
Industrial Videoscope System: This equipment utilizes most
advanced opto-digital technology, which takes inspection to a new
level of capability and versatility. It has a flexible tube with a camera,
which has a diameter of few millimeters (4.4 mm and 6 mm). This
insertion tube can be taken to areas, which are inaccessible
otherwise and can capture and reproduce images as accurately as
possible. This System has been used widely at CRM for inspection of
gearboxes and bearings.
Thermography supports maintenance of industries that have high
temperature processes. The technology helps pinpoint areas where
refractory material is wearing and allows repairs prior to catastrophic
failures. The technique is also used to find electrical components that
are hotter than normal. Such a condition usually indicates wear or
looseness. Thus, thermography allows performing maintenance on
particular electrical components. Other applications include the
monitoring of outdoor wiring such as overhead transmission lines,
which wear due to environmental conditions.
Condition Monitoring practices in CRM -Tata Steel:
The Cold Rolling Mill at TATA STEEL was commissioned in April 2000
.It has been built with state-of-the-art technology with following
facilities—
Facilities Suppliers
1. PL-TCM: 1.2 mtpa capacity MHI and HITACHI, Japan
2. Batch Annealing Furnace, 0.8 mtpa LOI, Germany
3. Skin Pass Mill, 0.8 mtpa IHI, Japan
4. CGL-1 : 0.1 mtpa FPE , India
5. CGL-2 : 0.3 mtpa CMI, Belgium
6. Recoiling Line 1 & 2 & 3 DBI, USA, & Bronx
7. Coil Packaging Line ITW & Indomag
5
CRM equipments are very complex and extremely costly. This

necessitates that the equipment and machineries must give higher
availability and reliability with ensured productivity. Right from the
beginning, a lot of stress has been given on condition monitoring
activities at CRM and it has resulted in substantial amount of savings
in the tune of few millions of rupees by avoiding catastrophic failures
and extension of process equipment life.
Condition monitoring activities at CRM may be differentiated, based
on four major aspects:
Off line monitoring

On-line surveillance system
Pro-active condition monitoring
Computerization of CM activities
Off line monitoring –
State of the art Condition monitoring instruments are being regularly
used in off line data capturing in the different work areas to ensure
the healthy condition of equipment. Thermal imaging, Vibration
analysis, Industrial Videoscope System, Ultrasounds, Oil analysis and
Ferrography techniques are being used regularly at CRM.
Following instruments have been procured by CRM.
1) Ferrography Machine (Located at MED, Mechanical)
2) CSI Vibration Data Collector compatible with CSI Vibration
Analysis Software at MED
3) Shock Pulse Meter
4) Machine Checker
5) Vib-10
6) Infrared Thermometer
7) Oil View (Located at MED, Mechanical)
6
8) Laser Alignment Instrument

9) Particle Counter
Following condition monitoring techniques are being used by CRM
personnel.
1) Vibration Analysis
2) Oil Cleanliness check by Particle Counter
3) Temperature measurement by infrared gun
4) Alignment by Laser Alignment Instrument
Central Condition Monitoring Group from MED, Mechanical is

providing support in the following areas.
1) Vibration Analysis
2) Thermography
3) Ultrasonic Thickness Measurement
4) DP Test
5) Ultrasonic Testing
6) Noise Measurement
7) Ferrography
8) Oil Testing
9) Industrial Videoscope System
On-line surveillance system –

Pickling Line and Tandem Cold Mill at CRM Complex is installed with
surveillance and full-fledged vibration spectrum monitoring systems,
to ensure the highest level of availability and reliability of mill. This
system allows on-line trend monitoring of temperature and vibration.
System configuration is given below.
7
Level 2
CRT
CMCS PR
F/D
Data FFT
collector
CMLS
Vibration Sensor CMLS
Vibration Sensor
Temperature Temperature
detector for PL detector for TCM
section section
This system consists of the following devices which are connected on

LAN ( FALCOnet).
(1) CMLS (Condition Monitoring Local Station)
The components are given as follows.
(a) PHENIX-IV
PHENIX-IV is a vibration meter that can switch up to 16
electrical charge input signals transmitted from piezoelectric
acceleration sensor. It divides an input signals into individual
frequency components of Low, Medium and High, detects
the average and peak value through Averaging and
Peakhold circuits and provides an output by converting them
in to 12 bits digital values.
(b) PHENIX-II
PHENIX-II is a data acquisition unit that has up to 16
insulation analog input points and provides an output by
8
converting voltage from the temperature sensor encoder or

current sensor encoder into 12 bits digital values.
(2) CMCS ( Cont. FFT)
CMCS (Cont. FFT) provides capabilities of editing or
storing measuring data which are transmitted from each
CMLS, and executing FFT calculation as needed. It can
connect to up to 144 CMLSs.
(3) CMCS (Win) provides capabilities of entering parameters
required for the equipment diagnosis, or displaying the
result of diagnosis and diagnosis requests with graphs. It
corresponds to a man-machine interface for the system.
CMLS Function:
1) Data sampling sub-system
Vibration: Average and peak value during certain period
2) Data check sub-system, including check of speed condition
3) Data conversion sub-system
4) Data transfer sub-system to CMCS
CMCS Function:
1) Data transfer sub-system
2) Data correction sub-system
3) Data averaging sub-system for 1 hour, 1day and 1 month
4) Data check sub-system for 1 day data
5) General diagnosis sub-system
• Average, peak value check
• Peak / Average value check
• Trend check for vibration and temperature
6) Data filing sub-system
7) Alarm report, daily report and monthly report
8) Trend graph display for vibration and temperature
9
9) FFT Analysis and diagnostic result by the operator’s request

Following equipments have been provided with sensors:
SR. EQUIPMENT MOTOR Mechanical
NO.
Bearing Air Temp. Winding Vibration
Vibration in air gap temp.
between
stator and
rotor
1 Pay-off Reel 2 1 1
2 Bridle No. 1 4 2 1
3 Tension Leveller 2 1 1
Roll
8 PL Entry Hyd. 7 7 7
Pumps
9 Mill Stand 1 2 1 1 1
10 Mill Stand 2 2 1 1 1
11 Mill Stand 3 2 1 1 1
12 Mill Stand 4 2 1 1 1
13 Mill Stand 5 2 1 1 1
14 Tension Reel 4 2 2 2
15 TCM Main Hyd. 6 6 6
16 Roll Coolant 6 6 6
10
Pumps
17 Fume Exhaust 2 2 2
Blowers
Pro-active condition monitoring
Oil particle monitoring and oil contamination monitoring of hydraulic
and lubricant oil are being regularly carried out at CRM as pro-active
measure to ensure the life of costly components. We have achieved
and maintained oil cleanliness level of NAS class - 2 in some
hydraulic systems. Our hydraulic oil cleanliness level in all systems is
below NAS-5. This has resulted in ten-fold increase in the life of
hydraulic components and avoidance of unforeseen stoppages of
mills because of malfunctioning of hydraulic systems.
Computerization of CM activities –
Database for all CRM Equipment which are covered under CBM, has
been created in CSI Vibration Analysis Software at MED. FFT
vibration signatures taken with the help of data collector are down
loaded to RBMWARE (CSI Software). Data trending and Diagnosis is
done through the software. Also CRM personnel can see equipment
health data like Vibration Overall values, Vibration Trends,
Temperature Trends, Ferrography observations etc. in their own
computer through Tribology Work Bench (TWB), an in-house
developed maintenance engineering software.
Saving Through Implementation Of Condition Monitoring:
A systematic practice of condition monitoring in different process

equipment helped CRM to achieve substantial bottom line benefits.
In the year 2002- 2003 benefits on account of implementation of
condition monitoring activities was more than Rs. 1 Crore. Benefits
of Condition Monitoring activities can be broadly classified in the
following heads:
11
A. Cost Saving By Preventing Failures. – CGL1 Furnace,

CGL1 Blowers
B. Life Extension of Process Equipment. –CGL1 & 2 Pot
C. Performance improvement. – Laser Alignment, Balancing,

Industrial videoscope system
Few cases are mentioned below in brief.

A) Cost Saving By Preventing Failures
Thermal imaging of CGL1 Furnace before MSD and repair during

MSD
In last two major shutdowns of CGL1, before shutdown,

thermography of entire annealing furnace was done and based on
this, area of refractory wear were identified. Based on this
information, refractory material was arranged well in advance and
repairs were done during the shutdown. By doing this, we could
prevent any line stoppage because of furnace refractory wear.
IR - I0000200.009
160.0 °C
150
100
50
0
0.0
09/05/89 01:00:23 PM
12
IR - I0000200.032
91.0 °C
90
80
70
60
50
40
30
30.0
02/08/01 00:09:01 PM
IR - I0000200.030
163.0 °C
160
140
120
100
80
60
40
20
20.0
13
02/08/01 00:00:58 PM
IR - I0000200.007
187.0 °C
180
160
140
120
100
80
60
48.0
09/05/89 00:47:19 PM
Ultrasonic Thickness Measurement of Radiant Tubes of CGL1:
In major shutdowns, Ultrasonic Thickness Measurement of Radiant

Tubes is also done. If any alarming reduction in thickness is found in
any one of the radiant tubes, it is changed to prevent failure during
line running.
FFT VIBRATION SPECTRUM AND SHOCK PULSE

MONITORING OF CGL1 & 2 BLOWERS.
14
FFT vibration Spectrum analysis, Trend monitoring and SPM

techniques are being regularly carried out to assess the health
condition of antifriction bearings of CGL1 AND CGL2 BLOWERS.
Proper diagnosis of FFT spectrum of vibration helped to detect bad
bearing and subsequently corrective action prevented catastrophic
breakdown in many Blowers.
CGL1 - RTF PILOT AIR BLOWER - 1

FAN-10 -F1A Fan Inboard Axial
1.4
RMS Velocity in mm/Sec
ROUTE SPECTRUM
1.2 07-May-02 10:25:34
OVRALL= 4.53 V-DG
1.0
RMS = 4.53
0.8 LOAD = 100.0
RPM = 2942.
0.6 RPS = 49.03
0.4
0.2
0
0 10 20 30 40 50 60 70 80
Frequency in Order
12 WAVEFORM DISPLAY
07-May-02 10:25:34
Acceleration in G-s
9
RMS = 3.82
6 PK(+) = 11.57
3 PK(-) = 12.45
0 CRESTF= 3.26
-3
-6
-9
-12
-15
Ordr: 1.000
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Freq: 49.03
Revolution Number Spec: .428
suggested for bearing change.
After removing the bearing from the system we found that bearing was badly damaged.
15
Following is the data of line outage (CGL1) because of blowers

before Condition Monitoring was implemented:
Sr. Description Month Outage

No. (Hours)
1. Chromate Exhaust Blower March,01 4
2. Blower 3 May,01 3
3. Preheat Combustion Blower 1 July,01 4
4. Blower 1 Sep,01 3
Average monthly outage = 14/7 = 2 hrs.
After implementation of Condition Monitoring of Blowers, there has

not been any line outage because of Blowers.
Down time cost of one hr. in CGL1 = Rs. 56,000
Saving = Rs. 1, 12,000 / month = Rs. 13,44,000 / year
B) Life Extension of Process Equipment –
CGL1 Pot
In CGL1, Zinc Pot is changed every six month. Once it comes out,
wear assessment is being carried out by doing ultrasonic thickness
measurement at various locations. After that, Pot is repaired by
depositing metal at portions where thickness has gone down. After
repair, pot thickness is again measured at various locations before it
is declared fit for use.
16
One no. of CGL1 Pot has already been repaired by this method and
put in service. Repair of 2nd pot is presently going on.
Saving: 14 Lakh (Cost of new pot in CGL1 = 14.4 Lakh, Cost of

manpower and consumable = 40,000 Rs.)
CGL2 Pot Repair
Auxiliary Pot No. 2 of CGL2 had leaked in the month of January

2002. The walls on the four sides were more or less seriously
corroded; the affected walls showed signs of hemispherical
depressions of varying sizes, up to a particular level in the pot. The
inter-compartmental steel barriers acting as stiffeners for the longer
sides of the pot were also badly eaten up; here too the depressions
were of the same nature, commonly known as golf –ball
depressions. The pot wall had drastically thinned down in the area of
the failure. The 50-mm thick wall had come down to 13 to 17 mm in
places where there was still some material left.
Apart from measuring the thickness of the wall along the line cut open
in the middle, for getting it repaired, the entire pot was checked by
ultra sonic probe to ensure the soundness of the undamaged
portions. The results did not show any major deviation.
The next step after the observations was to find the possible causes
of the failure. The potential causes that were thought of having
caused the failure were
A. Wrong material selection for the pot

B. Wrong fabrication process/ tools used (welding electrodes)
C. Bath temperature exceeding the safe limit of 480 o C
D. High bath temperature combined with turbulence in the bath,
aggravating the erosion of iron by the Aluminium in the bath
E. Localised hot spot in specific areas on the shell of the pot
F. Lack of temperature control on the bath and the different zones.
G. Combination of two or more of the above causes.
17
To investigate A (the material quality), samples drilled out from the

rim of the auxiliary pot no.2 were sent for metallurgical analysis.
Substantial differences were found from the ideal chemistry of the pot
material. However, the laboratory analysis matched the composition
of the suppliers’ specifications as given in the Test Certificate, but
differed from that of ARMCO steel, traditionally known as the ideal
material for zinc pot. As we gathered, the material for the pot was
imported from Thyssen, Germany, while the pot was fabricated at
TATA Growth Shop.
Fe C Mn S P Si
T.C. 0.057 0.38 0.0073 0.011 0.009
ACTUAL 0.04 0.37 0.011 0.013 0.015
ARMCO 0.015 0.08 0.015 0.02 Trace
This comparison underlines the doubt as to whether the composition

certified by Thyssen was ideally suitable for such applications.
The next task was to organize the repair of the pot. It had to be done
in-situ as the only available crane did not have the capacity of lifting
the 60 tonne weight (30t of the pot and 30t of the solidified zinc). This
proved to be a challenge in more than one way:
i. Space available was at a premium

ii. Working conditions in the cellar were fairly hazardous
iii. Time available to cut out the defective part and replace
with an appropriate material matching in every respect
with the parent material was only 10 days, (7th- 17th
January, 2002).
iv. Repairing involved certifying the material, testing the
material, preparing it , bringing it to the site, getting the
old surface ready, welding it in extremely carefully and
thoroughly, do necessary testing subsequently to verify
the soundness
Contrary to the apprehensions, getting the right material for the

repair proved to be the surest and the easiest of tasks. While the
parent material was originally imported from Thyssen, Germany, the
replacement material was specially cast and rolled in LD #2, Slab
18
caster to a plate of thickness of 50 mm. The plates were collected

from the transfer bar of the TISCO Hot Strip Mill and supplied to Tata
Growth Shop for fabrication. Non-destructive testing carried out on
the plates made sure that there was no flaw with the slabs meant for
repair. Suitably sized plates were cut out from the mother plates,
edge finished, and then put into the right place for making up the slot
cut out from the middle of the damaged pot. The four curved corners
were critical, as matching the profile of the plate with the rest of the
pot was a difficult task. This was accomplished with the help of a
template made at site and then used in the Growth Shop doing the
required preparations. After the welding repair was done, the joints
were tested by dye penetration test and all the debris were cleared
from the inside the pot.
After the repair job was over, the pot was stress relieved by heating
to 400 deg C, in two days time and then leaving it to cool by natural
convection.
Then came the task of the actual heating up of this auxiliary pot with
zinc ingots inside. An exhaustive temperature control and
measurement system was developed for heating up. Necessary
feedback obtained from the readings of the thermocouples helped
monitor the heating up the zinc filled pot.
Saving: 15.5 Lakh (Cost of New CGL2 Pot)
TOTAL SAVINGS BY IMPLEMENTING CONDITION MONITORING

AT CGL: 42.94 LAKH
C) Performance Improvement
Regular vibration monitoring of blowers and necessary correction

(Balancing, alignment, Foundation correction etc.) has resulted in
performance and reliability improvement of Blowers.
1) CGL1 Preheat Combustion Air Blower 1 Spectrum before and

after Balancing
19
CGL1 - PREHEAT COMBUTION AIR BL - 1

FAN-04 -F2H Fan Outboard Horizontal
24
Route Spectrum
07-May-02 09:50:45
21
OVRALL= 19.25 V-DG
RMS = 19.21
LOAD = 100.0
18 RPM = 2957.
RPS = 49.29
15
12
0
Ordr: 1.000
0 2 4 6 8 10 12 14 16 18
Freq: 49.29
Frequency in Order Spec: 18.76
CGL1 - PREHEAT COMBUTION AIR BL - 1

FAN-04 -F2H Fan Outboard Horizontal
24
Route Spectrum
31-May-02 17:20:35
21
OVRALL= 5.35 V-DG
RMS = 5.17
LOAD = 100.0
18 RPM = 3114.
RPS = 51.90
15
12
2) Spectrum
3 showing foundation bolt loose. Motor foundation bolt
was found loose and crack.
0
Ordr: 1.000
0 2 4 6 8 10 12 14 16 18 20
Freq: 51.90
Frequency in Order Spec: 4.227
20
2) Spectrum showing foundation bolt loose. Motor foundation bolt

was found loose and crack.
CGL2 - HOT AIR DRIER AFTER CHROMATI

HAD FAN-3 -M2V Motor Inboard Vertical
18 ROUTE SPECTR
29-May-02 10:
16
OVRALL= 15.95
14 RMS = 15.87
12 LOAD = 100.0
10 RPM = 2967.
8 RPS = 49.45
6
4
2
0
0 20 40 60 80 100
Frequency in Order
2.0 WAVEFORM DIS

29-May-02 10:
Acceleration in G-s
1.5
1.0 RMS = .7715
0.5 PK(+) = 1.83
PK(-) = 2.45
0
CRESTF= 3.18
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
Ordr:1.011
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Freq:50.00
Revolution Number Spec:15.28
21
We have also been using Laser Alignment Tool extensively, which

has resulted in reliability improvement of rotating equipment.
Alignment time has also reduced drastically by using this equipment,
which has resulted in increased availability of equipment.
Industrial Videoscope System has been used widely at CRM for

condition monitoring of Gearboxes and Bearings.
Recently, this instrument was used for inspection of SPM Tension

Reel Motor Bearings.
Scoring marks have been observed in Rollers and Races of SPM
Tension Reel Motor Bearings (Both Drive Side and Non Drive Side)
through Videoscope which shows initial deterioration of the bearings.
Ferrography reports also show bearing particles in the oil. Based on
this observation, we have changed over to new synthetic oil for
lubrication and bearing are under constant watch for any further
deterioration.
Some of the Photographs taken from Videoscope are shown below.
22
23
Conclusion:
Condition monitoring and pro-active maintenance is today a key part
of industrial asset management. Now, Maintenance is not considered
as a necessary cost but as a strategic asset. Maintenance influences
the entire operation, from product quality to on-time delivery. Poor
maintenance procedures lead to substantial amount of cost
expenditure for repairing and poor quality and lost production —
whereas good maintenance practices can cut production costs
immensely. Predictive maintenance is designed to help organization
to optimize the effective use of machines and assets in order to
maintain a cost competitive advantage in their respective market
place.
References:
1. C. Mishra, J.K. Takkar and T.C. Alexander,

Tata Search, 1997- Achieving Breakthroughs
in Maintenance
2. G.R.P. Singh, A.K. Chaterjee, H.K. Gupta, A.
Ranjan and H.C. Kharkar, Tata Search,2000-
Maintenance System Design for Cold Rolling
Complex
24

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IMPROVING EQUIPMENT AVAILABILITY AND RELIABILITY

G.R.P. Singh, A.K. Paul, A.K. Chaterjee, P.S.S. Ganesh, C. Mishra

examined to enhance profitability. To be more competitive industry,

CBM is carried out for two main reasons:

1.To detect sudden changes in condition that could lead to

2. To identify the early onset of incipient failures so that a prediction

implementation of condition monitoring can reduce the maintenance

Oil and Wear-Particle Analysis: Oil analysis and wear-particle

CRM equipments are very complex and extremely costly. This

 Off line monitoring

8) Laser Alignment Instrument

Central Condition Monitoring Group from MED, Mechanical is

On-line surveillance system –

This system consists of the following devices which are connected on

converting voltage from the temperature sensor encoder or

9) FFT Analysis and diagnostic result by the operator’s request

Saving Through Implementation Of Condition Monitoring:

A systematic practice of condition monitoring in different process

A. Cost Saving By Preventing Failures. – CGL1 Furnace,

B. Life Extension of Process Equipment. –CGL1 & 2 Pot

C. Performance improvement. – Laser Alignment, Balancing,

Few cases are mentioned below in brief.

Thermal imaging of CGL1 Furnace before MSD and repair during

In last two major shutdowns of CGL1, before shutdown,

Ultrasonic Thickness Measurement of Radiant Tubes of CGL1:

In major shutdowns, Ultrasonic Thickness Measurement of Radiant

FFT VIBRATION SPECTRUM AND SHOCK PULSE

FFT vibration Spectrum analysis, Trend monitoring and SPM

CGL1 - RTF PILOT AIR BLOWER - 1

suggested for bearing change.

Following is the data of line outage (CGL1) because of blowers

Sr. Description Month Outage

Average monthly outage = 14/7 = 2 hrs.

After implementation of Condition Monitoring of Blowers, there has

Down time cost of one hr. in CGL1 = Rs. 56,000

Saving = Rs. 1, 12,000 / month = Rs. 13,44,000 / year

B) Life Extension of Process Equipment –

Saving: 14 Lakh (Cost of new pot in CGL1 = 14.4 Lakh, Cost of

CGL2 Pot Repair

Auxiliary Pot No. 2 of CGL2 had leaked in the month of January

A. Wrong material selection for the pot

To investigate A (the material quality), samples drilled out from the

This comparison underlines the doubt as to whether the composition

i. Space available was at a premium

Contrary to the apprehensions, getting the right material for the

caster to a plate of thickness of 50 mm. The plates were collected

Saving: 15.5 Lakh (Cost of New CGL2 Pot)

TOTAL SAVINGS BY IMPLEMENTING CONDITION MONITORING

Regular vibration monitoring of blowers and necessary correction

1) CGL1 Preheat Combustion Air Blower 1 Spectrum before and

CGL1 - PREHEAT COMBUTION AIR BL - 1

CGL1 - PREHEAT COMBUTION AIR BL - 1

2) Spectrum showing foundation bolt loose. Motor foundation bolt

CGL2 - HOT AIR DRIER AFTER CHROMATI

2.0 WAVEFORM DIS

We have also been using Laser Alignment Tool extensively, which

Industrial Videoscope System has been used widely at CRM for

Recently, this instrument was used for inspection of SPM Tension

Some of the Photographs taken from Videoscope are shown below.

1. C. Mishra, J.K. Takkar and T.C. Alexander,

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Off line monitoring